High protein edible products and method of preparing same

ABSTRACT

HIGH PROTEIN EDIBLE PRODUCTS AND THE METHOD OF PREPARING SAME ARE DESCRIBED. A BAKED, LEAVENED PRODUCT INCLUDES A NON-ELASTIC PROTEIN SUCH AS SESAME OR A CONBINATION OF SESAME AND SOY BEAN, AN ELASTIC TYPE VEGETABLE PROTEIN SUCH AS WHEAT GLUTEN OR WHEAT GLUTEN IN COMBINATION WITH EDIBLE GUMS, AND FLAVORING AND TEXTURING AGENS INCLUDING VEGETABLES. CRACKERS AND CEREAL ARE MADE USING A MUCH LOWER AMOUNT OR ELIMINATING THE ELASTIC TYPE VEGETABLE PROTEIN.

Oct. 10,, 1972 C. C. LYNN HIGH PROTEIN EDIBLE PRODUCTS AND METHOD OFPREPARING SAME I Filed Nov. 25, 1969 STEP 1 BASE MATERIAL NON -ELASTICPROTEIN,OIL, SEASONING,FLAVORING,ACID

COMBINED AND HEATED STEP 2 INTERMEDIATE PRODUCT VEGETABLES, WATERNON-ELASTIC PROTEIN MEAL;

THICKENING AGENT AND MOLD INHIBITOR ADDED STEP 3A BLEND IN ELASTICVEGETABLE PROTEIN, OTHER PROTEIN MATERIAL CHEMICAL LEAVENER AND MIX TOFORM DOUGH STEP 4A CUT DOUGH TO SHAPE AND REST STEP 5A BAKE IN OVEN STEP3B DEHY DRATE STEP 4B BLEND IN ELASTIC VEGETABLE PROTEIN, OTHER PROTEINMATERIAL AND CHEMICAL LEAVENER STEP 58 ADD WATER TO FORM DOUGH STEP 6BCUT DOUGH TO SHAPE AND REST STEP 7B BAKE IN OVEN INVENTOR CHARLES 0. mm

United States Patent Ofice 3,697,290 Patented Oct. 10, 1972 3,697,290HIGH PROTEIN EDIBLE PRODUCTS AND METHOD OF PREPARING SAME Charles S.Lynn, 102-30 66th Road, Forest Hills, N .Y. 11375 Continuation-impart ofapplication Ser. No. 846,428, July 31, 1969. This application Nov. 25,1969, Ser. No. 879,717

Int. Cl. A21d 13/04, 13/06 US. CI. 99-86 18 Claims ABSTRACT OF THEDISCLOSURE CROSS REFERENCE TO RELATED APPLICATION This application is acontinuation-in-part of my copending application, Ser. No. 846,428,entitled, High Protein Edible Product and Method of Preparing Same,filed July 31, 1969, and now abandoned.

BACKGROUND OF THE INVENTION The present invention relates to highprotein edible products of both the leavened and unleavened variety andto methods of producing same.

DESCRIPTION OF THE PRIOR ART In one process commonly used in making aconventional loaf of bread, a sponge dough is prepared comprising flour,water, yeast, yeast food and sugar. Yeast is required for thefermentation or leavening. The sponge dough stands for three and a halfto four hours during which leavening occurs. Thereafter, the balance ofthe ingredients is added to the dough; that is, more flour, more water,some milk solids and other necessary ingredients. A kneading procedureis followed. The water must be under a controlled temperature. Afterkneading, the dough rests for one-half to one hour. The dough is thenplaced in a divider which cuts the dough into desired weights. Thedivided dough is next passed into a molder. From the molder, the moldeddough goes onto a pan which passes the molded dough into a temperatureand humidity controlled proof box, during which time fermentation takesplace. After approximately one hour in the proof box, the loaves ofleavened dough pass into the oven where the baking takes place. Thebaking time varies with the type and size of the bread. The overall timein making the bread is approximately six to seven hours.

Conventional breads so prepared are generally quite low in protein, butquite high in carbohydrates. For example, ordinary white breads containapproximately 8 /2 to 9% protein, and rye breads generally no more than9%. At the same time such breads have a carbohydrate level on the orderof 48% to 52%.

Apart from the above-mentioned disadvantages, conventional breads have avery short shelf life, due to loss of moisture, loss of flavor andstaling. Rye bread, for example, is noticeably drier after two to threedays. With other breads, staling is noticeable in no more than one week.

More recently, the protein level of conventional breads has beenincreased by the addition of fortifiers such as more milk solids, extragluten, soy bean flour, cotton seed flour; that is, oil seed grains fromwhich the oil has been removed. What is being done here is that some ofthe starches are being replaced by the fortifiers, thereby reducing thecarbohydrates and increasing the protein level. Such techniques haveincreased the protein level to approximately 11% to 12% without,however, any improvement in processing time or procedure, and with noincrease in shelf life.

With most grains such as wheat and rye, of the basic constituents, thegreatest proportion is carbohydrates 0r starches. A smaller proportionis protein, and a very small portion is fat. In contrast, in oil grainseeds, the greatest proportion is fat; a smaller proportion is proteinand the least amount is the carbohydrate. Therefore, when the fat isremoved from the oil grain seed, one is left with a nonelastic, highprotein content material.

It has been suggested to add to conventionally baked breads, sesame,processed in some manner to remove its green taste, and added in smallquantities to the conventional flour. Sesame seeds have also been usedas a topping on baked products to add flavor.

SUMMARY OF THE INVENTION An object of the invention is to use anon-elastic protein such as the oil seed grain as a major constituent ina high protein edible product of low carbohydrate content.

Another object is a high protein baked, leavened, edible product of lowcarbohydrate content.

Still another object is such a product requiring no yeast for leaveningaction.

A further object is such a product with an appreciably longer shelflife.

A still further object is the obtaining of products such as bread-likeloaves by a process requiring much shorter processing time, onlysimplified equipment and relatively unskilled help.

The foregoing objects of the present invention are accomplished bystarting with an non-elastic type protein material. Assuming that theultimate product desired is a baked, leavened product, then thisnon-elastic type protein material is combined with an elastic typevegetable protein and various texture and flavoring agents includingvegetables to produce a bread-like textured edible product. The taste,'texture and structure of the product is created in a process in whichthe tendency of the elastic type vegetable protein, typically a wheatgluten, to expand or swell, is controlled or counteracted, within a bodyof non-elastic type protein material, typically sesame meal, alone or incombination with soy bean meal, corn meal, etc. The vegetables, whichcan be of the leaf, root or grain type, not only act as an extender orcarrier for the other materials, but also add materially tothe textureand flavor of the food product.

The process of manufacture provides a leavened loaf or baked edibleproduct which can be made in about one and a half hours compared to thesix to seven hours of the prior art; requires fewer steps in the processof manufacture with a resultant considerable saving in time, labor andexpense; uses more simplified equipment in the process of manufacture,and, hence, less labor skill; provides a baked leavened edible productof high protein content of from to 40%, but preferably between and and alow carbohydrate content of from 15% to but preferably between 20% and30% (on the total basis of the whole tfin'ished loaf), compared toconventional breads; has a long shelf life of two'to three times theshelf life of conventional breads, and resembles in taste, appearanceand overall character, a bread, and yet requires no yeast for theleavening and, therefore, no leavening time is required. Anotheradvantage is that a minimum of cleaning of the equipment is required inthe process of manufacture, for example, no or little dusting orgreasing of the baking equipment is needed. Still another advantage isthat no emulsifiers, artificial softeners, or conditioners to extend theshelf life of the bread (except for a mold inhibitor) are required inthe making of the baked, leavened edible product of the invention, ascompared to the making of conventional breads.

By means of the present invention, one is able to create a high proteinand low carbohydrate loaf which has an exceptional overall food value.The loaf or roll of the invention provides the high nutritional value ofa well balancedfood with a perfectly enjoyable liporganic character at amoderate cost.

The preparation of the bread itself is simple and requires so littleskill andequipment and a relatively wide range of ambient environment toproduce that it becomes practical to manufacture the loaf or roll undermany conditions and circumstances where normal bread production isextremely ditficult and often impossible. In most instancesthe proteincontent of a leavened loaf made in accordance with the invention exceedsby approximately more than twice the protein content of averagecommercially available breads, and with very good amino acid and mineralvalues. In the manufacture of the bread of the invention, the indoorambient temperature normally encountered in the temperate zones may varyover a wide range and have very little efiect on the process andresulting product. Normal drinking water from the tap, having atemperature range anywhere from 40 to 90F., preferably 60 to 80 F., maybe used in the process of the manufacture without deleteriouslyaffecting the end product.

Other edible product requiring yeast leavening, can be produced inaccordance with this invention without yeast and with the numerousadvantages pointed out above. Examples of such products are danishpastries and coffee cakes.

In accordance with another aspect of the present invention other nonyeast-leavened items can be made. For example, a cracker or cereal canbe made by reducing ,the amountof elastic protein material, only enoughbeing included to create: enough adherence or by completely eliminatingsame.

Additionally, the material of the present invention can be used as aprotein fortifier for rye and wheat breads, cereal, noodles and thelike.

BRIEF DESCRIPTION OF THE DRAWING The foregoing and other objects,features and advantages of the. invention will be apparent from thefollowing, more particular description of the preferred embodiments ofthe invention as illustrated in the accompanying drawing, wherein theflow diagram illustrates the steps followed and materials used in thenovel method and obtaining the novel product of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the drawing,the flowchart depicts in a broad manner the novel process of the presentinvention. In step 1, formation of the base material, a nonelastic typeprotein, oil, seasoning, flavoring and acid are combined and heated.

The non-elastic type protein can be hulled, chopped, or comminutedsesame seeds preferably in the range of 25% to 50% by weight. In oneexample extracted sesame meal was used in combination with sesame seeds.As noted above, the non-elastic material serves as a high-proteinsource. Other non-elastic type proteins that can be used are soy bean,cotton seed, etc.

A variety of oils, preferably in the range of 35% to 50% can be used,for example, vegetable oil made from sesame, cotton seed oil (preferred)and soy bean oil. The preferred bland vegetable oils have virtually noodor or taste. Other oils such as soy bean oil should be avoided unlessdeodorized. A quantity of salt, preferably in the range of 12% to 25%,is included for seasoning.

The foregoing three elements are heated togetherv with occasionalstirring at a low simmering temperature, ap-,

ever, if a mild acid other than citric acid is used, the pH will vary sothat weight percentage amounts will change slightly.

The caraway are included mainly for their rye-type flavoringcharacteristics although they are beneficial to the texture. Oil ofcaraway may be used instead of the caraway seeds. Similarly, oleo resincaraway (an oily liquid substance) may be used having the flavorcharacter of. caraway seeds. If either of the foregoing substitutes areused for the caraway seeds themselves, then a proper adjustment of thesubstitutes must be made to achieve desired flavoring. The resultingmaterial from the foregoing steps is dark, brown, oily and sandy inappearance. The caraway need not be included in this step but could beadded in the following step 2.

In step 2, formation of the intermediate product, vegetables, 'water,non-elastic protein meal, a thickening agent and a mold inhibitor areadded to the base material formed in step 1. Optionally, the moldinhibitor can be introduced at step 3.

Initially, the vegetables are added to the base material along withwater and boiled for a period of time depending on the vegetables used.A wide variety of vegetables of the leaf, root or grain type can beused. Vegetables are included for their flavoring characteristics and ofcourse the taste characteristic will vary somewhat with the vegetablesused. Examples of vegetables that can be used are potatoes, corn, sugarbeets, parsnips, turnips,

carrots, parsley, parsley roots, cabbage, etc. Spinach and parsley willproduce an odd color in the finished product. Normally the vegetablesare used in their raw state. However, many can also be used in dry formsuch as corn meal for corn, potato flour for potatoes, etc.

After the boiling of the foregoing combination, additional water andnon-elastic protein meal are added and the entire mass is brought backto. the boiling temperature for another short period depending on thematerials used. Examples of non-elastic protein meals are extractedsesame meal, cotton seed meal and soy bean meal.

The non-elastic protein meal is preferably fat free. The defatting ofthe non-elastic protein meal is done by a solvent extraction process, orby an expeller extraction process using heat low enough so as not todenature the protein, or by a-combination of solvent extracted andexpeller extracted material.

At this point a thickening agent, preferably farina made from wheat orcorn isadded and cooking continues. The thickening agent is required tocreate a desirable texture. Other thickening agents can be used such aswheat or corn starch or wheat flour.

To inhibit the propagation of mold, a suitable, acceptable amount ofinhibitor conforming with the Food and Drug Administration Regulationscan be added, for example, sorbic acid or potassium sorbate or a verysmall percentage of propyl paraben.

This completes the cooking stage and the resulting material is a mashwhich is brown-greyish in color. At this point a person has the optionof either dehydrating the Wet material and storing, or continuing withthe wet material.

Pursuing with the wet material and with reference to step 3A in thedrawing, there is added to the material an elastic vegetable protein,other protein materials and a chemical leavener. The material is blened,mixed and kneaded into a dough. Optionally, other materials can be addedat this point to modify flavor and texture characteristics.Representative of these materials would be wheat flour, albumen, cheese,etc.

A typical elastic vegetable protein is wheat gluten. Wheat gluten can beobtained from wheat by different processes. After it is Washed out itcan be spray dried or it can be dried by other means. Spray dried glutenis generally much lighter by weight and therefore more readily lendsitself to formation of the desired cellular structure. However, thetaste and general palatability in the final product is not as good asglutens prepared by other methods.

A portion of gluten can be replaced with edible vegetable gums such ascarboxymethyl cellulose gum, seaweed gums, gum tragacanth, etc. Verygood results have been achieved by replacing a certain proportion ofgluten with a cellulose gum. Corn gluten has virtually no resiliency andtherefore not desirable.

Also added to the material are certain additional sources of protein,for example, whole eggs, a mixture of casein, lecthin, albumen and waterand commercially available milk solids. A chemical leavener such asbaking powder, bicarbonate of soda or a combination of both is blendedin.

After thoroughly blending, the resulting mixture constitutes a doughwhich may be removed from the mixing bowl and cut into desired sizes(step 4A) and molded in the usual fashion into the desired shape ofbread-like loaf or rolls, etc. where it is rested for preferably, butnot necessarily, 10 to 20 minutes and then baked (step 5A) in an oven toform a baked, leavened bread-like product.

It should be observed that the wet base material already contains mostof the water necessary to form the dough. Hence, if desired, the eggsolids, non-fat milk solids, wheat gluten and chemical leavener can becombined in the dry form before adding to the wet base material. In thiscase a slight adjustment of the water content should be made to balancethe moisture normally present in whole eggs.

Merely adding the contents of the two combinations together both Wet anddry, and thoroughly blending will produce the dough. It will, therefore,be understood that the wet base material can be sold in a frozen statein a package while the dry ingredients can be sold in another packageand both thoroughly mixed to form the dough which is subsequently moldedinto the shape of a loaf of bread or a roll.

Permitting the molded loaf to rest at normal room temperature causes thematerial therein to relax, thereby helping to create the desired shapeor a more controlled shape of the loaf or roll when subsequently baked.Less desirable shape properties result when the dough is placed in anoven without rest.

The cut and shaped material is then placed into any conventional oven ata temperature of approximately 400 to 450 F. It requires a baking timevery much like a regular bread or cracker as the case may be.

During this baking time, the dough rises and leavening occurs, as aresult of which the loaf or roll or pastry has the appearance and tasteof a conventional loaf of bread or pastry with the usual cellularstructure.

A further advantage is that the dough of the invention does not stick tomost materials, particularly to metals. The pan or oven hearth,therefore, need be treated with very little or no flour or grease andthe loaf will virtually leave no mark on the processing equipment at thebaking stage.

In the dry process, the brown-greyish material resulting from step 2 isdehydrated to obtain a dry base material at step 3B. This dry basematerial may then be stored. Subsequently, the dry base material can beblended with an elastic vegetable protein, other protein materials and achemical leavener (step 4B), water added to form a dough (step 5B) andprocessed (steps 6B and 7B) to form bread, rolls or pastry as explainedabove.

A cracker product, with some slight variations in steps 1, 2 and 3A or4B can be produced. In step 3A or 4B the amount of elastic type proteinis reduced. Also, snack items or cereal can be produced with very slightchanges in the process steps. In step 3A or 4B, for example, most or allof the elastic type protein material is eliminated and replaced with ahigher proportion of edible gums, starches or combinations of both. Alsothe chemical leaveners are reduced or eliminated.

The following examples are included merely to aid in the understandingof the invention, and variations may be made by one skilled in the artwithout departing from the spirit of the invention.

EXAMPLE 1 Base material:

Chopped sesame seeds..- 1 34 Vegetable oil 1 43 Combined and simmered atSalt (NaCl)... 1 17 300350 F. for minutes. Citric acid.-. 1 1 Carawayseeds.-. 1 5 Heating continues for 30 nutes. lntelamediate product: 2

arsnips'm I 1 0 Combined and boiled to r Camts- 30 20-25 minutes at 215-230 F. 1 450 }Cooking continues for 20-26 Ground sesame mea1 1 150minutes. Farina 1 60 Cooking continues for 5-15 I minutes. Final rmx:

Intermediate product. 1 1, 000 Whole eggs 1 -200 Blended. Moldinhibitor... 1 '2 wg i igi Blended to form dough, then Baking powder 115 rest for 15-20 mmutes.

1 Grams.

The cut and shaped loaf is placed in a conventional oven at 400450 F.and baked. The dough rises, leavening occurs and the resulting loaf hasthe appearance and taste of a conventional rye bread with the usualcell-like openings in the loaf. The finished product has a proteincontent above 25% and a carbohydrate level of no more than 25 EXAMPLE 2Base material:

Ground sesame Cottonseed oil. Salt 1 100 1 Heat and slow simmer 1%hours.

l 1 15 Add and continue heating hour.

approximately 24% and a carbohydrate level of 24%.

EXAMPLE 3 EXAMPLE 6 Base material: Base material: 7

Ground sesame 1 100 Ground sesame 1 150 Cottonseed oiL. 1 125 Heat andslow simmer for Cottonseed oil 1 138 Simmer 15 minutes. Salt 1 47 75minutes. 88 Citric acid 3 011210 acid 7.5 4 30 a 4 Ground caraway 1 15Ai i dnga nd continue heat 56 ggtlglgggdcgelggfiyglgf. n 1% 3 Add andsimmer mmu s. lntemedliiate product I 30 Integgggigg: product 1 100 Criots 1 10 Boil 25 minutes Base mate 1 165 }Boil 10 minutes. v ma 1%Water; i Add and bring back to boil 8.8T- Water- 1 200 Add and boil 15minutes 10 Extracted sesame meal... 1 125 Extrac 1 60 more. White cornmeaL"; 1 50 Add and boil 25 minutes. Farina... 1 Add an? cook 5 more 1 6272 minu es. I Remove from heat; sorbjc acid 1 2' 5 }Add and cook 5minutes blend in gram Final mix: 1 whole eggs, 0.5 gram. Npnfat milksolids potassium sorbate 15 Bicarbonate of soda... 1 2 th Final mix:Baking powder l 6 Blend toga er.

a assess S fiifariematefiit soda.. 1 Blend together i riigelgneegagtiarztliductnu 1 2 3(8) Add and blend. ose our...-. y lnteg'gl gdiateproduct 1 100 Add tohabove and knead to a Cellulose gum 1 2 andkneaddoug 20 1 Grains: 1 Grams.

3 ro- The resulting product placed in an oven and baked t i 3; 335 zapproxlmately 2 P as above contains approximately 23% pmtem and 28% 25end gr c iiicts acl i ievc ad from the various steps are carbchydrates'interchangeable. For example, base material from Example 1 can be usedin intermediate product of Example EXAMPLE 4 3, a nd itnterriigdiatepergduct 3 can be used in the final mixing s ep 0 xamp 3m material: 1 30While the invention has been particularly shown and Heat n Slow Simmerdescribed with reference to the preferred embodiments 1 75 minutesthereof, it will be understood by those skilled in the art 1 15 Addgndcontinue heating that various changes and omissions can be made therein0111. Intermediam product; without departing from the spirit and scopeof the in lgarsley roots 138 vent om Base material I 100 B011 20 mmutes-What is claimed is: watg 1g; 1. In the process of preparing a highprotein edible,

o Extracted sesame meal 1 150 and b01120 m inutes' P p compnsfng a gg 325g ggggg ggif 40 a combining non-elastic protein material, 011 and salt0 e e s Sol-bio fie 1 1.5 then add and blend in. n heating at a 10Wslmmerms temperature, 31 milk lid 1 15 75 adding a mild acid to theforegoing and continuing 0 a S0 S Baking l2 25}B19ndtogethe1- heatingfor a per od of time suflicient to bring out Wheat 2 uten 1 4 7. Add ndknead to a dou h flavor characteristics; Intermedme pmduc a g addingwater and vegetables and boiling; 1 Grams. adding additional water andnon-elastic protein material and continuing boiling; and, addin athickening agent and continuing boiling to obg The resultingbakedproduct has a protein content of m an intermediate f d product of hlghPmtem 29% and 23% Ydrates. content with desired texture, flavor andblending characteristics.

2. The process according to claim 1 wherein said non- EXAMPLE 5 elasticrotein material is an oil seed rain.

p I g o a Base material: 1 2m 3. The process according to claim 1wherein said noni iHeat and I er 20 mmutes' j I h e go c s z i ii g iz iwherein said non 1 s a s c Ground Caraway 1 40 and Simmer 20 minuteselastic protein material ncludes sesame and soybean. Extracted sesamemeal--. 1 100 5. The process according to claim 1 wherein said vegeg fgf Pmduct no tables include potatoes.

1 110 6. The process according to claim 1 wherein said thick- 1 gig Boil20 minutes' ening agent is farina. 600 p 7. The product produced inaccordance with the proc- E Do 1900 Add and br ng back to boil. 688 ofclaim 1' xtracted sesame meal--- 280 Add and boil 20 minutes. 8 Th d t 11 l d b Farina.-. .d. 1 11 2 and cook 5 minutes. e PI'OCESS acc r lng oc 31m Inc 11 mg Com 111' mg said intermediate product with an elastictype vege- Nonis't milk solids 30 table protein and leavener to form adough, molding said gi Iwwder 1 4 dough into a desired shape, and bakingto form a baked,

icarbonate of soda 2 All purpose flour i 43 Blend together. leavened,break-like product. g'gfigf g fifl a a' g g g? 9. The process accordingto claim 8 wherein said elastic Water. 1 180 Add and knead. typevegetable protein includes gluten. 1 The dough, when baked, results in afinal product comprising 27% The Process q g to 6131111 8 wherein saidprotein and 24% carbohydrates. elastic type vegetable protein includesgluten and an edible vegetable gum.

11. The process according to claim 8 including adding The dough, whenbaked, results In a final Product further protein sources including milksolids prior to bakprising 27% protein and 24% carbohydrates. ing.

12. The process according to claim 8 including resting said dough priorto baking.

13. The process according to claim 8 including dehydrating saidintermediate-product to form a dry base material and then combining withan elastic type vegetable protein, and water to form said dough.

14. The product produced in accordance with the process of claim 8.

15. The process according to claim 1 including combining saidintermediate product with an elastic type vegetable protein to form adough and baking to form a baked product.

16. The product produced in accordance with the process in claim 15.

17. The process according to claim 1 including combining saidintermediate product with edible gums,

UNITED STATES PATENTS 5/1965 Gabby et a1. 99-86 2/1963 Koolhaus 9990 HP10 RAYMOND N. JONES, Primary Examiner J. R. HOFFMAN, Assistant ExaminerUS. Cl. X.R..

15 99-17, 99 HP, 90 S, 90 NS

